WO2007019009A2

WO2007019009A2 - Process for 360 degree soft touch molding on an object core and product made therewith

Info

Publication number: WO2007019009A2
Application number: PCT/US2006/028247
Authority: WO
Inventors: Richard B. Fox
Original assignee: Polyworks, Inc.
Priority date: 2005-08-03
Filing date: 2006-07-20
Publication date: 2007-02-15
Also published as: WO2007019009A3; US20070031595A1

Abstract

A process for making a soft touch outer surface for an object includes the steps of first providing a core (44) to receive a soft touch outer surface thereon and providing a mold member (40, 42) having a mold cavity (50). The core (14) is then placed inside the mold cavity (50). A low durometer elastomer, having a Shore 00 hardness of 70 or less, or a low density foamed plastic, having a specific gravity of specific gravity between 0.1 and 0.7 is injected into the mold cavity (50) to surround the core (44) in 360 degrees to provide a predetermined thickness of a cushioning layer. The core (44), with cushioning layer (52) thereon, is demolded from the mold (40, 42) by which it was formed. The outer surface of the cushioning layer is then covered with a finish layer (56).

Description

PROCESS FOR 360 DEGREE SOFT TOUCH MOLDING ON AN OBJECT CORE AND PRODUCT MADE THEREWITH

CROSS-REFERENCE TO RELATED APPLICATIONS

[oi] This application claims priority from prior U.S. Provisional

Application Serial No. 60/705,279 filed on August 3, 2005.

BACKGROUND OF THE INVENTION

[02] The present invention generally relates to the process of creating an

ergonomic handle, grip, or other such small object that is comfortable to the

touch. More specifically, the present invention relates to the process of

creating a grip or a small object wherein a rigid or semi-rigid interior

component, such as a core, is fully encased in a molded superstructure of

low durometer elastomer, such as urethane, or a low density foamed plastic

and the surface thereof is painted or covered with fabric for aesthetics and

durability.

[03] In the prior art, there are various objects, surfaces and substrates that

are hard to the touch. There is a desire to make those surfaces more

comfortable for human contact. Also, it is desirable to make the surfaces

more ergonomic where contact with the human body can be better

positioned for optimal use of the underlying article.

[04] In the prior art in general, cushioning material is applied to or

secured to an underlying substrate in a number of different ways. Rubber materials or other relatively higher durometer elastomers have been

molded around objects in the prior art. These materials differ from the

cushioning layer in the present invention in that they are of a higher

durometer than shore 00 hardness of 70 and are thus significantly firmer

that the elastomers or foams prescribed herein. These higher durometer

materials can be molded in traditional injection molding equipment. The

lower durometer elastomers utilized in the present invention cannot be

molded by traditional injection molding equipment. They have very long

cure times and are generally extremely tacky. The present invention

describes a process wherein these lower durometer and low density

materials can be successfully molded in 360 degrees around a rigid or semi

rigid core.

[05] The higher durometer cushioning materials such as rubber provide

better friction with fingertips or hands than hard plastic, but have very

limited ability to conform to finger shape under pressure when compared to

the low durometer elastomers and low density foams described in the

present invention.

[06] Low durometer (below shore 00 hardness of 70) have been utilized in

a non-molded manner as a cushioning layer for a grip in the prior art. In a

first prior art example 10, as seen in Fig. 1, an extruded tube 12 of low

durometer elastomer, having unitary thickness is expanded and then slid over an object core 14 to be cushioned and then contracted (by heat

shrinking, for example) to provide a layer of cushioning to the core. More

specifically, the object core 14 is a flashlight body which communicates with

the hands of a user. The tube 12 of cushioning material is slid onto the

flashlight body 14 with the assistance of a lubricant material. In this

example, while the tube 12 of cushioning material assumes the shape of the

rigid core 14 beneath, i.e. cylindrical, where the cushioning layer 12 is of a

uniform thickness profile over the core 14. In other prior art attempts, low

durometer material is commonly cast as a sheet or web and then applied to

the surface of the rigid core as a wrap or patch.

[07] In a second prior art example 20, as seen in Fig. 2, a low durometer

liquid gel 22 is contained within flexible bags 24 and is sealed within an

outer cylindrical sleeve 26 which could be rubber or plastic. The result is a

cylindrical bag or series of bags 24 filled with gel 22 that is then slid over the

body of the core 28, such as a tool handle, for cushioning thereof. The bags

24 are sandwiched between the underlying object core 28 and the sleeve

layer 26 which is also typically also slid over the liquid-holding bags 24.

Thus, to provide the very low durometer liquid cushioning, bags 24 must be

used which are extremely limited as to how they can be configured on the

object core 28. In other prior art, low durometer materials have been used

as a dip or coating to again apply a uniform thickness to an object. [08] The primary shortcoming of prior art methods, that employ low

durometer elastomers as cushioning, is that the low durometer materials are

applied in a constant thickness about the substrate. Thus, the substrate itself

defines the outer configuration and shape of what the article will look like

after the cushioning material has been applied. Essentially, prior art

cushioning layers with low durometer elastomers are simply added layers

that make the finished article slightly larger where the outer layer of

uniform thickness is now a cushioning layer. The low durometer material

being of uniform thickness does not allow for the ergonomic designs

incorporating more or less cushioning material at various places within the

object. It also limits the aesthetic appeal of the finished product, since a

uniform outer layer reduces the ability to achieve a highly detailed shape in

the finished object.

[09] As noted previously, prior art rubber grips or higher durometer

elastomers are molded in shapes that are not uniform but they do not

exhibit the highly desirable conforming visco-elastic properties of the low

durometer elastomers or low density foamed plastics. Low durometer

materials with long cure times and extreme tackiness cannot be molded

using prior art methods, particularly, in non-uniform thicknesses.

[10] In view of the foregoing, there is a need for a process which can

create a grip or object that has a low durometer or low density material applied as a non-uniform coating or layer of cushioning. There is a need for

a cushioning layer on a substrate that can have variable thicknesses at

different points over the substrate as well as varying amounts of

cushioning. There is a need for a cushioning material that is able to be

molded directly to a substrate, surrounding it in 360 degrees and finished, if

desired. There is a need for a low durometer cushioning layer around an

object that can have a detailed and attractive appearance.

SUMMARY OF THE INVENTION

[11] The present invention preserves the advantages of prior art processes

for 360 soft touch molding on a substrate and products made therefrom. In

addition, it provides new advantages not found in currently available

processes and products and overcomes many disadvantages of such

currently available processes and products.

[12] The invention is generally directed to a novel and unique process for

forming a cushioning layer about a core, which could be, for example, a

writing instrument, a tool handle, the handle of a razor, an eyeglass frame

or beverage container.

[13] The process for making a soft touch outer surface for an object

includes the steps of first providing a core to receive a soft touch outer

surface thereon and providing a mold member having a mold cavity. The

core is then placed inside the mold cavity. A low durometer elastomer, having a Shore 00 hardness of 70 or less, or a low density foamed plastic,

having a specific gravity of specific gravity between 0.1 and 0.8 is injected

into the mold cavity to surround the core in 360 degrees to provide a

predetermined thickness of a cushioning layer. The core, with cushioning

layer thereon, is demolded from the mold by which it was formed. The

outer surface of the cushioning layer is then covered with a finish layer.

[14] It is therefore an object to provide process for forming an outer

cushioning layer for an object core to make interaction with that object more

comfortable and ergonomic.

[15] It is an object of the present invention to provide a process for

forming a cushioning layer for an object core that is softer and more

comfortable than prior art cushioning layers.

[16] It is a further object of the present invention to provide a process for

forming a cushioning layer that is more customizable and flexible than prior

art processes.

[17] Another object of the present invention is to provide a process that

can form a cushioning layer that has a non-uniform profile thickness over

the surface of the underlying core object.

BRIEF DESCRIPTION OF THE DRAWINGS

[18] The novel features which are characteristic of the present invention

are set forth in the appended claims. However, the invention's preferred embodiments, together with further objects and attendant advantages, will

be best understood by reference to the following detailed description taken

in connection with the accompanying drawings in which:

[19] Fig. 1 is a perspective view of a prior art uniform thickness

cushioning layer that has been slid onto an object core;

[20] Fig. 2 is a cross-sectional view of an object core that is cushioned by a

number of liquid-containing bags with a outer cylindrical sleeve thereabout;

[21] Fig. 3 A is a top view of a first mold half with a object core loaded

therein in accordance with the present invention;

[22] Fig. 3B is a top view of a second mold half that is matable with the

first mold half of Fig. 3A in accordance with the present invention;

[23] Fig. 4 is an elevational view illustrating a finish layer being sprayed

onto the outer surface of the mold part in accordance with the present

invention;

[24 ] Fig.5 is an elevational view illustrating a finish layer being applied to

the molded part by dipping in accordance with the present invention;

[25] Fig. 6 is an elevational view illustrating a tubular finish layer being

applied to the molded part in accordance with the present invention;

[26] Fig. 7 is a cross-sectional view through the line 7-7 of Fig. 4 in

accordance with the present invention; [27] Fig. 8 is a cross-sectional view through the line 8-8 of Fig. 5 in

accordance with the present invention; and

[28] Fig. 9 is a top view of the in-line process of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[29] In accordance with the present invention, a new and novel process

for 360 degree molding on and/or about a substrate is provided. More

specifically, the process of the present invention provides an effective

method of creating a grip or small object that has a rigid or semi-rigid core

and is covered in 360 degrees with low durometer or low density material

which has differing thickness at various points over the core substrate. The

process is outlined below can be carried out for providing a finished

cushioned layer to any object core, such as a barrel of a writing instrument

or tool handle. For ease of discussion, the process of the present invention is

described in detail herein in connection with the process of forming a

finished cushioned layer on the barrel of a writing instrument, however, this

is just one example of how the process of the present invention can be

implemented. The formation of finished cushioned layers on any other type

of object core is within the scope of the present invention.

[30] Referring first to Figs. 3 A and 3B, a first mold half 40 and a mating

complementary second mold half 42 are prepared with a mold release

coating 53 and pre-heated. A mold release 53, such as 19mdr (axel plastics), is preferably employed but other suitable release materials can be used.

Also, known methods for heating molds is used, such as infrared or electric

heaters. In Fig. 3A, the pen barrel 44 is loaded and seated in place within

cavity 50 on the first mold half 40. The second mold half 42 is mated with

the first mold half 40 to thereby close about the barrel 44. Next, the desired

cushioning material 52, such as urethane with a Shore 00 hardness in the

range of 20-65, is injected therein via input gate 46. Material less than Shore

00 hardness of 55 is preferred. Output gate 48 is also provided to

accommodate overflow. The balancing of the materials and curing thereof

is then automatically executed. Multiple molds are preferably used to

improve production efficiency and increase capacity.

[31] As will be described in connection with Fig. 9 below, the molds 40, 42

proceed through the process by conveyor in series to allow for the long

curing time of the low durometer elastomer or low density foam plastic

material. The process is timed and contains the appropriate number of mold

frames such that the molded part reaches the demolding step in the process

at a point where the elastomer or foam has cured. The mold 40, 42 is then

opened and the part is unloaded. Sprew materials are removed to clean up

the part. The outer surface of the cushioning later is then optionally painted

or coated with a fabric layer to provide an outer finish layer. It is also

conceived as part of the present invention, that the rigid or semi rigid core can be of sufficient length so that it could be cut into multiple finished parts

after the molding process. This can further enhance the efficiency of the

process for grips or objects whose shape permits this.

[32] The material used in the present invention is preferably a low

durometer elastomer, as mentioned above. However, it is also

contemplated that the material could also be a low density foamed plastic

with a specific gravity between 0.9 and 1.45. This foamed plastic could be

foamed Polyurethane, Polyethelene, EVA or other material.

[33] Unlike the very low durometer and very low density materials

employed in the present invention (e.g. shore 70 and below), rubber and

higher durometer materials, such as urethanes and high density foams are

used in the prior art. These higher durometer materials do not have the

tackiness or long cure times and can thus be molded by standard injection

molding processes. Because of the tackiness, the low durometer products

need to be molded with no flashing since they cannot be trimmed. Also,

they require specialized release coatings in the molds to allow them to come

out of the mold and still be painted. The long cure times of these materials

are accommodated by utilizing numerous molds moving in series through

the process.

[34] Once the molding material is formed about the core, they are

preferably finished with a finish layer. For example, the parts 54 can be painted or covered with a tubular knit or braided fabric to attain a desirable

aesthetic and durable finish. As in Fig. 4, the resultant part, generally

referred to as 54, includes the desired object core 44, which in this case is a

pen barrel, and outer layer of low durometer or low density foamed

material 52. In Fig. 4, the finish layer 56 is a layer of paint that has been

sprayed onto the outer surface of the cushioning material 52 by spray guns

58. Thus, the tacky cushioning layer 52 is now sealed and finished to

provide an attractive and comfortable cushioned pen barrel. Moreover, the

paint can be selected to be a certain color to further enhance the aesthetics of

the finished part 54.

[35] Also, as in Fig. 5, the finish layer 56 can be alternatively formed by

dipping the core 44 and cushioning material 52 thereon into paint reservoir

60. Still further, the finish layer 56 can be a tubular fabric, as seen in Fig. 6,

where it is slid over the core 44 and cushioning material 52 thereon. The

fabric 56 be adhered to the outer surface of the cushioning material 52 by

many different ways, such as by heat shrinking or by adhesive.

[36] Where the prior art does use low durometer materials in cushioning

of small objects and grips, they are used in sleeves, tubes, sheets or dips

which provide only for uniform thickness of cushioning over a substrate. In

contrast, the molding technique used in the present is unique and novel

over the prior art because it can provide different profiles of low durometer elastomer or low density foam about the surface of the substrate. For

example, the region of the cushioning layer of a pen barrel that is positioned

underneath the thumb and middle finger may be thicker than the rest of the

cushioning layer to provide additional cushioning where the user's fingers

contact the pen barrel. For example, Fig. 7 shows a cross-sectional view

through the line 7-7 of Fig. 4 and Fig. 8 shows a cross-section view through

the line 8-8 of Fig. 4 to illustrate that the process of the present invention is

capable of providing different thickness profiles over the surface of the

same part 54. In this example, Fig. 7 shows that the cushioning layer 52 in

the middle of the pen barrel is less thick than the cushioning layer 52 under

the user's fingers which is shown in Fig. 8. This ability is unique to the

process of the present invention.

[37] Also, a given area may be injected with higher or lower durometer

material than other parts of the layer. In the pen example, the regions

under the thumb and middle finger may be lower durometer material or

may be of a thicker profile for added comfort and to assist the user in

ergonomically orienting the pen body in their fingers.

[38] Thus, in accordance with the present invention, varying profiles of

cushioning material with varying thicknesses and hardnesses can be

provided over the surface of the substrate and applied to the substrate in a

single 360 degree molding operation to form a unique and novel cushioned product. A significant and important advantage of the low durometer

materials of the present invention is that they often exhibit visco-elastic

properties and thus conform to the shape of the hand or other contact point.

[39] In accordance with the present invention, other finished products of

different molding materials can be formed using the 360 molding process of

the present invention. These include, pen barrels, shaving razor handles,

hand tools, brushes, toothbrushes, eyeglasses, lint brushes, toys and

novelties as well as luggage handles and drinking bottles or other liquid

containers. In general, any substrate could be molded 360 degrees

therearound using the process of the present invention.

[40] An outer finish layer 56, such as paint or fabric, although optional, is

preferably provided. This finish layer that covers around the low

durometer or low density cushioning layer 52 is often critical since the low

durometer elastomers are generally very tacky and/or not durable to the

touch. It is critical that the paint or fabric utilized have a significant amount

of stretch to be able to conform to the movement of the low durometer

cushion layer.

[41] Also, instead of paint or fabric, various films may be applied to the

360 degree molding part to further enhance the article. For example, a soft

outer polyurethane film can be applied to the low durometer elastomer on a

pen barrel to provide an outer skin. These alternative films can be applied using similar techniques as described in connection with Figs. 4-6. Other

films can be utilized depending on the application or requirements. These

films can be polyurethane, Polyester, Polypropylene, Nylon, Polyethelene

or other appropriate material. These films can be printed or painted before

or after applying them to the object. These films may be applied as tubes or

wrapped around the object. In general, depending upon the shape, it may

be desirable for the film layer to have heat shrink properties. In this way

the film can be shrunk after application to conform directly to the object

shape. In general, the outside surface of the 360 degree molded material can

be further modified to suit the application at hand.

[42] Example: Beverage Container

[43] Below is a summary outline of the steps in connection with the

process of the present invention in an example, as shown in Fig. 9, where

the object core is a rigid barrel insert for a writing instrument. The materials

that are used require and extended cure cycle to cure and are very tacky

until they are finished with a painted coating or covered with a fabric finish

layer tube.

[44] 1. Mold preparation - the mold halves 3 A, 3B are coated with a

release coating, at location #1, to prevent the tacky cushioning material 52

from sticking to the molds 3A, 3B which would damage the parts 54 or the

molds 3A, 3B or both. [45] 2. Mold pre-heating - the mold halves 3A, 3B are preheated at

location #2 to reduce the gel time so molds are not evacuated as they are

turned upside down as the machine indexes.

[46] 3. Object Core Loading - object cores 44, namely, an inner barrels

of a writing instrument, such as pen, are automatically loaded and

positioned with high tolerance, at location #3, to insure precisely matched

component during post assembly.

[47] 4. Automated inner barrel seating - to insure that the positioned

inner barrels 44 are seated against the positive stops prior to indexing to the

mold closing station at location #4.

[48] 5. Automated closing of the molds - the molds, of the type

shown in Figs. 3 A and 3B, are a two piece design and are laying flat and

open until the inner barrel is placed and positioned. Then^-rrfolds halves 3A,

3B are automatically close and then locked at location #5.

[49] 6. Injection of Cushioning Material. The chemical component

mix is automatically injected into the closed mold 3A, 3B at location #6. The

soft touch grip cushioning material 52, which could be a low durometer

elastomeric material or low density foamed plastic, is injected. In this

example, a low durometer elastomer is preferred for a pen barrel 44. It is in

a liquid state therefore positioning of the injection heads #6 to the molds 3A,

3B is critical, the dose and delivery of the chemicals to the mold is also critical as variations will cause changes in the softness of the finished pen

part 56. The system 100 provides for a dual injection system which permits

the molding of two different materials which may have different

characteristics, such as different durometers or specific gravities.

[50] 7. Automated balancing of materials. The materials in the mold

are automatically balance in the filled mold at location #6 to reduce spew

size and scrap.

[51] 8. Automated curing. After the molds are filled with the

cushioning material they are indexed at location #7 around an over / under

chain conveyor #8, this allows the parts 56 to cure while the system 100 is

performing the operations 2-7 above.

[52] 9. Automated opening of the closed molds. The molds 3 A, 3B

are unlocked and opened to allow molded parts to be unloaded or

demolded at location #9. The use of a release coating facilitates this process.

The design of the opener as well as the mold carriers is critical as we must

not bend or break the inner barrel during this process step.

[53] 10. Removal of sprew materials. This process is carried out to

clean up the molded part prior to application of the finish layer at location

#10.

[54] 11. Indexing of parts for finish layer application. The molded

parts are unloaded and loading onto the automated coating line at location #11. Parts are placed on carriers custom designed to process the soft touch

pens. The carriers are attached to a chain conveyor that indexes the

uncoated parts to a painting / coating station at location #11.

[55] 12. Automated painting of the parts. Preferably, up to (3) paint guns

#12 to apply the custom formulated coating of paint 56 at location #12. The

guns #12 automatically index up and down as the soft touch pen parts 56

are turning and moving through this station. Automated rotation of the

molded parts insure 360 coverage of the finish layer coating.

[56] 13. Automated curing of coated parts. The coated parts are

conveyed through a series of positions in a heated environment at location

#13.

[57] 14. Unloading of parts. The parts are unloaded and placed in

cartons for post curing at location #14.

[58] In view of the foregoing, a new and improved process for 360 degree

molding around a substrate and product made therewith is provided. With

the 360 degree molding process of the present invention, materials can be

effectively applied 360 degrees on a substrate to provide a superior end

product that has comfort and ergonomics that cannot be formed using

known prior art techniques for applying these low durometer or low

density materials. [59] It would be appreciated by those skilled in the art that various

changes and modifications can be made to the illustrated embodiments

without departing from the spirit of the present invention. All such

modifications and changes are intended to be covered by the appended

claims.

Claims

WPiAT IS CLAIMED IS:

1. A process for making a soft touch outer surface for an object,

comprising the steps of:

providing a core to receive a soft touch outer surface thereon;

providing a mold member having a mold cavity;

placing the core inside the mold cavity;

injecting a low durometer elastomer, having a Shore 00 hardness of

70 or less, into the mold cavity to surround the core in 360 degrees with a

predetermined thickness;

demolding the core with low durometer elastomer thereon having an

outer surface; and

covering the outer surface of the low durometer elastomer with a

finish layer.

2. The process of claim 1, wherein the finish layer is paint.

3. The process of claim 2, wherein the paint is elastomeric.

4. The process of claim 2, wherein the paint is an elastomeric

polyurethane.

5. The process of claim 2, further comprising the step of:

spraying paint onto the outer surface of the low durometer

elastomer.

6. The process of claim 5, further comprising the step of:

rotating the core 360 degrees during the step of spraying paint onto

the outer surface of the low durometer elastomer.

7. The process of claim 2, further comprising the step of:

covering paint on the outer surface of the low durometer elastomer

by dipping.

8. The process of claim 1, wherein the finish layer is fabric.

9. The process of claim 8, wherein the fabric is tubular in configuration.

10. The process of claim 8, wherein the fabric is made of a material

selected from the group consisting of braided, circular knit and heat

shrinkable.

11. The process of claim 1, wherein the finish layer is film.

12. The process of claim 11, wherein the film is made of a material

selected from the group consisting of: polyurethane, EVA, polyethylene,

polyester, nylon and polypropylene.

13. The process of claim 1, wherein the core is rigid.

14. The process of claim 1, wherein the core is semi-rigid.

15. The process of claim 1, wherein the core is a writing instrument.

16. The process of claim 1, wherein the core is handle of a razor.

17. The process of claim 1, wherein the core is an eyeglass frame.

18. The process of claim 1, wherein the core is a beverage container.

19. The process of claim 1, wherein the low durometer elastomer has a

cure time of greater than 1 minute.

20. The process of claim I₁ wherein the low durometer elastomer has a

cure time of greater than 3 minutes.

21. The process of claim 1, wherein the mold member is made of plastic.

22. The process of claim 1, further comprising the step of:

covering the mold member with a non-transferring release agent

prior to injecting the low durometer elastomer into the mold cavity.

23. The process in of claim 22, wherein the release agent is cross-linked.

24. The process of claim 1, wherein the predetermined thickness of the

low durometer elastomer is of a non-uniform profile around the core.

25. The process of claim 1, wherein the mold member includes a

plurality of mold components moving in series to allow curing of the parts

in a continuous fashion.

26. The process of claim 1, further comprising the step of:

transporting the core and low durometer elastomer thereon on a

conveyor during curing of the low durometer elastomer.

27. The process of claim 1, wherein the core is made of injection molded

plastic.

28. The process of claim 1, wherein the core is made of metal.

29. The process of claim 1, further comprising the step of:

injection molding the core in-line prior to the low durometer

elastomer.

30. The process of claim 1, wherein the core is of sufficient length to

make multiple parts when cut post molding.

31. A process for making a soft touch outer surface for an object,

comprising the steps of:

providing a core to receive a soft touch outer surface thereon;

providing a mold member having a mold cavity;

placing the core inside the mold cavity;

injecting a low density foamed plastic, having a specific gravity

between 0.1 and 0.7, into the mold cavity to surround the core in 360

degrees with a predetermined thickness;

demolding the core with low density foamed plastic thereon having

an outer surface; and

covering the outer surface of the low density foamed plastic with a

finish layer.

32. The process of claim 31, wherein the finish layer is paint.

33. The process of claim 32, wherein the paint is elastomeric.

34. The process of claim 32, where the paint is an elastomeric

polyurethane.

35. The process of claim 32, further comprising the step of:

spraying paint onto the outer surface of the low density foamed

plastic.

36. The process of claim 35, further comprising the step of:

rotating the core 360 degrees during the step of spraying paint onto

the outer surface of the low density foamed plastic.

37. The process of claim 31, further comprising the step of:

covering paint on the outer surface of the low density foamed plastic

by dipping.

38. The process of claim 31, wherein the finish layer is fabric.

39. The process of claim 38, wherein the fabric is tubular in

configuration.

40. The process of claim 38, wherein the fabric is made of a material

selected from the group consisting of braided, circular knit and heat

shrinkable.

41. The process of claim 31, wherein the finish layer is film.

42. The process of claim 41, wherein the film is made of a material

selected from the group consisting of: polyurethane, EVA, polyethylene,

polyester, nylon and polypropylene.

43. The process of claim 31, wherein the core is rigid.

44. The process of claim 31, wherein the core is semi-rigid.

45. The process of claim 31, wherein the low density foamed plastic is

made of a material selected from the group consisting of: polyurethane,

polyethylene and EVA.

46. The process of claim 31, wherein the core is a writing instrument.

47. The process of claim 31, wherein the core is handle of a razor.

48. The process of claim 31, wherein the core is an eyeglass frame.

49. The process of claim 31, wherein the core is a beverage container.

50. The process of claim 31, wherein the low density foamed plastic has a

cure time of greater than 1 minute.

51. The process of claim 31, wherein the low density foamed plastic has

a cure time of greater than 3 minutes.

52. The process of claim 31, wherein the mold member is made of

plastic.

53. The process of claim 31, further comprising the step of:

covering the mold member with a non-transferring release agent

prior to injecting the low density foamed plastic into the mold cavity.

54. The process in of claim 53, wherein the release agent is cross-linked.

55. The process of claim 31, wherein the predetermined thickness of the

low density foamed plastic is of a non-uniform profile around the core.

56. The process of claim 31, wherein the mold member includes a

plurality of mold components moving in series to allow curing of the parts

in a continuous fashion.

57. The process of claim 31, further comprising the step of:

transporting the core and low density foamed plastic thereon on a

conveyor during curing of the low density foamed plastic.

58. The process of claim 31, wherein the core is made of injection molded

plastic.

59. The process of claim 31, wherein the core is made of metal.

60. The process of claim 31, further comprising the step of:

injection molding the core in-line prior to the low density foamed

plastic.

61. The process of claim 31, wherein the core is of sufficient length to

make multiple parts when cut post molding.